MODULE DC/DC CONVERTERS

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1 MODULE DC/DC CONVERTERS DC/DC AC & DC POWER SOLUTIONS

2 APPLICATION DC/DC converters are designed to convert the voltage from a power source to the voltage required by load devices. They enable regulation output voltage. The galvanic insulation between the input and output circuits of the DC/DC converter means that it can be used in systems of batteries and loads with opposite poles earthed or to connect an earthed system with an unearthed system. DC/DC converters are used in 220 V (110 V) battery-powered systems in order to obtain low voltages (24 V or 48 V). The converters take advantage of redundancy to ensure a highly reliable power supply to low-voltage loads, making it unnecessary to use back-up batteries (24 V or 48 V). An uninterrupted supply to the low-voltage devices is provided by a 220 V (110 V) battery in combination with the DC/DC converter. DC/DC converters can be used to supply high-voltage loads (220 V or 110 V) from a 24 V or 48 V battery supply. It is then unnecessary to use a 220 V or 110 V battery. The main benefit of using DC/DC converters is a reduction in the number of battery-based supply systems with different rated voltages, which saves the costs of installing and maintaining the additional batteries. Back up time of all loads is the same. 220V~ 220V~ 220V~ 220V~ Classic multi-battery system 220V= 48V= 220V= 48V= Single-battery system with converters 19" Rack with DC//DC converters STANDARDS AND CERTIFICATES The device complies with the IEC146 standard. DC/DC converter for mounting in 19" cabinet An ISO9001:2000 quality certificate covers development work, design, manufacture and servicing of industrial electronic products. AC & DC POWER SOLUTIONS

3 PRINCIPLE OF OPERATION The DC/DC converter consists of a voltage inverter with transistors (IGBT or MOSFET), a high-frequency transformer, and an output rectifier with filter. The inverter converts the DC input voltage into a high-frequency AC wave. The transformer then ensures that the amplitude of this wave corresponds to the required output voltage, and provides galvanic insulation between the input and output circuits. The transformer's output voltage is rectified and filtered. The DC/DC converter's output voltage is regulated and stabilized by PWM (pulse width modulation) technology. To increase the reliability of the output power supply, DC/DC converters are manufactured as redundant systems, e.g. with a redundancy of 2/3. This means that a single rack contains three identical DC/DC converters designed to operate in parallel. The output power of any two converters is sufficient to supply the loads. During normal operation the load is distributed between the three converters, each of them supplying one third of the output power. Should one of the converters fail, the remaining two will continue to supply power to the loads. The failed converter can then be replaced (without the need to switch off the power supply). The rack containing the DC/DC converters is fitted with a set of fuses which protect the circuits of the individual converters. Versions can be produced with different levels of redundancy (1/2, 2/3) and different numbers of converters operating in parallel. 110V= 220V= 48V= 110V= 220V= Block diagram of DC/DC converter 1/2P 1/3P 1/2P P 1/3P P 1/3P Redundant system (2/3) in case failure of one converter Redundant system (2/3) during normal operation MODULE DC/DC CONVERTERS

4 Configuration diagram: SDCDC SAMPLE CONFIGURATIONS OF TWO-BATTERY POWER SUPPLY SYSTEMS Two-battery power supply system with common energy distribution bus The two-battery system with common energy distribution bus enables loads to be powered independently from either the first or the second battery. This increases the reliability of the power supply. One of the batteries can be disconnected for maintenance or testing. Two-battery power supply system with separate energy distribution buses The two-battery system with separate distribution buses enables loads to be powered independently from either the first or the second battery. Electricity is supplied to each load along two lines. Immediately before each load, a diode system selects the source with the highest voltage value (earthed system). This prevents interruptions to the power supply caused by failure of one of the supply lines. The reliability of the power supply is thereby increased. One of the batteries can be disconnected for maintenance or testing. AC & DC POWER SOLUTIONS

5 CATALOGUE DATA DC/DC converters for installation in a 19" rack DCDC W 220 V 24 V 15 A DCDC W 220 V 48 V 10 A DCDC W 110 V 24 V 15 A DCDC W 110 V 48 V 10 A DCDC W 48 V 220 V 3 A DCDC W 48 V 110 V 5 A DCDC W 24 V 220 V 3 A DCDC W 24 V 110 V 5 A for installation in a 19" cabinet DC/DC converters DCDC W 220 V 24 V 125 A DCDC W 220 V 48 V 75 A DCDC W 125 V 24 V 125 A DCDC W 125 V 48 V 75 A DCDC W 110 V 24 V 125 A DCDC W 110 V 48 V 75 A for installation in a 19" rack DC/DC converter systems with 2/3 redundancy SDCDC W 220 V 24 V 30 A (45 A) SDCDC W 220 V 48 V 20 A (30 A) SDCDC W 110 V 24 V 30 A (45 A) SDCDC W 110 V 48 V 20 A (30 A) for installation in a 19" cabinet DC/DC converter systems with 2/3 redundancy SDCDC W 220 V 24 V 250 A (375 A) SDCDC W 220 V 48 V 150 A (225 A) SDCDC W 125 V 24 V 250 A (375 A) SDCDC W 125 V 48 V 150 A (225 A) SDCDC W 110 V 24 V 250 A (375 A) SDCDC W 110 V 48 V 150 A (225 A) for installation in a 19" rack DC/DC converter systems with 1/2 redundancy SDCDC W 48 V 220 V 3 A (6 A) SDCDC W 48 V 110 V 5 A (10 A) SDCDC W 24 V 220 V 3 A (6 A) SDCDC W 24 V 110 V 5 A (10 A) MODULE DC/DC CONVERTERS

6 TECHNICAL PARAMETERS DC/DC converters for installation in a 19" rack W Power supply Input voltage 220 V 110 V 48 V 24 V Acceptable range of voltage changes (rated output parameters) -15 % +15 % Acceptable range of voltage changes (operation) -25 % +35 % Peak input voltage 350 V= 250 V= 160 V= 63 V= Dielectric test 2.8 kv 60 s Output parameters Rated output voltage 48V 24V 220V 48V 24V 220V 110V 220V 110V Rated output current 10A 15A 3A 10A 15A 3A 6A 3A 6A Efficiency 90 % 85 % Output voltage regulation -2 % +2 % Over voltage protection +10 % Stabilization of voltage at the protection level Limitation of output current 1.03 In Stabilization of current at the limit level Measurement of output current each 10 % In Row of LEDs Alarms Input voltage out of range LED marked Input voltage OK switches off, -25 % +35 % Failure Alarm relay triggered Output voltage out of range LED marked Output voltage OK switches off, -10 % +5 % Disturbance Alarm relay triggered Converter operating Alarm LED switches on, +10 % with over voltage limitation Disturbance Alarm relay triggered Converter operating Alarm LED switches on, 1.03 In with current limitation Disturbance Alarm relay triggered Converter operating Alarm LED switches on, 1.03 In with short circuit at output Disturbance Alarm relay triggered Alarm relays Max. operating voltage 300 V= lub 250 V~ Max. load capacity 4 A dla 220 V~ 0.3 A dla 220 V= Ambient conditions (storage and operation) Operating temperature 0 40 C Storage temperature C Relative humidity (noncondensing) max. 98 % Installation site altitude below 2000 m Air cooling natural EMC Class B Enclosure Degree of protection IP20 Mounting of housing 19" rack housing Number of slots 3 2 Dimensions of a single slot DCDC220-xx-xx DCDC48-xxx-x DCDC110-xx-xx DCDC24-xxx-x height 262 mm 262 mm depth 232 mm 232 mm width 71 mm 106 mm Dimensions of box with slots height depth width 266 mm 244 mm 483 mm AC & DC POWER SOLUTIONS

7 DC/DC converters for installation in a 19" cabinet W Power supply Input voltage 220 V 125/110 V Acceptable range of voltage changes (rated output parameters) -15 % +10 % -15 % +10 % Acceptable range of voltage changes (operation) -25 % +25 % -20 % +25 % Peak input voltage 320 V= 200 V= Dielectric test (input) 2.8 kvdc 60 s 1.4 kvdc 60 s Dielectric test (output) 700 VDC 60 s Output parameters Output voltage rating 48 V 24 V 48 V 24 V Output current rating 75 A 125 A 75 A 125 A Efficiency 91 % 88 % Regulation of output voltage -15 % +15 % Over voltage protection +20 % Stabilization of voltage at the protection level Limitation of the output current 1.03 In Stabilization of current at the limit level Measurement of the output voltage each 0.1 V alphanumeric display of the output current each 1 A alphanumeric display Alarms Output voltage above +14 % LED marked Voltage out of tolerance Change of level of over voltage alarm +8 % +20 % switches on, message HIGH OUTPUT displayed, Fault Alarm relay triggered Output voltage below LED marked Voltage out of tolerance -2 % switches on, message LOW OUTPUT displayed, Fault Alarm relay triggered Input voltage below LED marked Voltage out of tolerance -25 % -20 % switches on, message LOW INPUT displayed, Fault Alarm relay triggered Output current above LED marked Overload switches on, In message OVERLOAD displayed, Fault Alarm and Disturbance Alarm relays triggered Alarm relays Max. operating voltage 300 V= or 250 V~ Max. load capacity 4 A for 220 V~ 0.3 A for 220 V= Ambient conditions (storage and operation) Operating temperature 0 40 C Storage temperature C Relative humidity (noncondensing) max. 98 % Installation site altitude below 2000 m Air cooling natural EMC Class B Enclosure Degree of protection IP20 Mounting of housing 19" cabinet Number of slots 3 Dimensions of a single slot height depth width 132 mm 518 mm 483 mm Dimensions of enclosure with slots height depth width 900 mm 570 mm 483 mm MODULE DC/DC CONVERTERS

8 AC & DC POWER SOLUTIONS MEDCOM Sp. z o.o. Founded in 1988, active in the design, manufacture, installation and servicing of modern electronic devices, aimed mainly at the power industry, military, railway and tramway transport, industry and health service customers. The use of latest technologies and system solutions, the services of highly experienced structural designers and the introduction of an ISO 9001:2000 Quality Assurance System, ensure that the devices manufactured are stateof-the-art and highly reliable. The technical design for all products is carried out in-house. In 2001 the company was awarded a prize The Polish President's Economy Award for THE BEST POLISH SMALL ENTERPRISE. The most important products in the company's offer: DC power supplies Uninterruptible power systems High-voltage power supplies Power supplies (MIL standards) Static converters for railway and tramway applications Power supplies for industrial applications Power active filters Traction battery chargers Static transfer switches Fail-safe power supplies Motor driving systems: AC and DC motors Measurement devices: battery earth fault meters, battery operation monitors Wind power converters MEDCOM Sp. z o.o. 28/30, Barska Street tel , , Warsaw, Poland fax Since we are constantly incorporating the latest technological advances, our products are subject to modification. For this reason it may happen that certain elements of the above descriptions are no longer valid. DCDC 03/03 EN

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